Temperature controlled, auto timed, variable amperage cascading-water furmation method for use with high antimony and maintenance free lead-acid batteries

ABSTRACT

A novel formation method is disclosed which is compatable for use in forming high antimony as well as, maintenance free (i.e., low antimony calcium, etc.) batteries. The method includes constant circulation of a cooling fluid around the batteries to be formed while the batteries are stepped through various charging cycles of different lengths and currents. The preferred method is a &#34;one shot&#34; method, thus eliminating the necessity of adding successive electrolyte solutions to the batteries. Unlike prior &#34;one shot&#34; formation techniques, however, formation times are relatively short while plate clearance characteristics and the completeness of formation are excellent.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of my copending U.S. Pat.application Ser. No. 821,527, filed Aug. 3, 1977 now U.S. Pat. No.4,117,387 entitled, "CASCADING-WATER, LEAD-ACID STORAGE BATTERYNEUTRALIZATION FORMING AND CHARGING METHOD", which application isincorporated herein by reference as if fully set forth herein.

The present application is also related to co-pending U.S. Pat.application Ser. No. 866,301 filed Jan. 3, 1978, entitled"cascading-water, lead-acid storage battery neutralization, forming andcharging apparatus."

BACKGROUND OF THE INVENTION

In a modern battery production facility, the ability to form batteriesis an important aspect of that facility's ability to meet fluctuatingseasonal demands for fully formed and charged batteries. Since thesedemands peak in the winter months, it has become commonplace formanufacturers to make an inventory "duff" (dry-unformed) batteries whichare filled with electrolyte and formed immediately prior to shipmentduring periods of peak demand. Accordingly, the "peak load" capacity ofa given battery manufacturing facility depends to some extent upon theability of that facility to form batteries.

The advent on a significant commercial scale of "maintenance freebatteries" has further added to the problem of satisfying seasonaldemands, since market fluctuations which may depend to a certain extenton local weather conditions make it difficult, if not impossible, toaccurately predict the percentage of a given battery plant's productionwhich must be formed as either conventional "high-antimony" product, or,alternatively, as a "maintenance free" product.

Heretofore, most battery production facilities included rectifiationequipment designed to supply a constant voltage to continuously chargehigh-antimony batteries, which voltage was selected on the basis of theformation characteristics of those batteries. For maintenance freebatteries, on the other hand, which do not tend to gas as much ashigh-antimony batteries, which have a higher end-of-charge voltage andwhich may be relatively more prone to thermal runaway, relatively highercharging voltages have been preferred to effect the electro-chemicalchanges which occur during formation. While these constant voltage ormodified constant voltage techniques have experienced considerablesuccess, the sharp drop in currents which accompany later stages of thisprocess significantly retard the overall formation time, particularlywith maintenance free batteries which have higer end-of charge voltages.

In many battery facilities, in order to aid in formation and counteractsomewhat the effect of gassing and chemical heat produced by theaddition of electrolyte to dry, unformed batteries, "two shot" formationmethods have been employed wherein relatively lower specific gravityacids are first introduced into the batteries and then are replaced withrelatively higher specific gravity acids near the completion of theforming process to provide a "finishing charge" to those batteries. Inaddition to obviating certain problems with "plate pickling" which areassociated with the introduction of relatively higher gravity acids todry unformed battery, the "two shot" process of forming batteries hasusually been considered to exhibit better plate clearancecharacteristics and more complete conversion of battery oxides intosponge lead etc. than a "one shot" process. Accordingly, most batterymanufacturers have preferred a "two shot" formation process for reasonswhich include (1) formation time required; (2) fewer problems withoverheating and/or thermal "runaway"; and (3) the clearingcharacteristics obtained therewith for fully charged or nearly fullycharged battery plates.

Although it has long been known to utilize a variable amperage chargingmethod for charging and/or re-charging lead acid storage batteries,variable amperage charging methods have not generally been applied bythe battery industry to form storage batteries due, at least in part, tothe electro-chemical complexities of such a process, particularly inview of the disparate battery capacities and types routinely formed in anormal commercial battery production facility.

Another classical formation problem in the battery industry iscontrolling temperature and time of battery formation. When electrolyteis first added to an unfilled, unformed battery and interacts with thepaste on the plates of the element assembly within the battery, a greatdeal of heat is generated; this heat being referred to as the heat ofneutralization. Heat continues to be generated by the battery during theformation and charging process while high current flow is presentedthrough the batteries. It is uneconomical to purchase and maintainsufficient equipment to form batteries at a current low enough toprevent the heating of the batteries.

Various means have been devised to cool batteries during theneutralization, formation, and charging process in order to avoidinternal overheating of the batteries which, if not properly controlled,results in destruction of the battery. The problem of dissipating heatwhich is generated during the formation of a battery has been aggravatedby the widespread use of plastic battery cases throughout the automotivebattery industry. Unlike rubber, composition, or glass cases previouslyused by the industry, plastic cases tend to have a low heat transfercoefficient which tends to insulate the interior of the battery makingit particularly susceptible to overheating problems.

Several approaches, such as circulating water baths in which batteriesstand in low rows of tanks permanently erected on the floor of theforming room have been used in attempts to dissipate the heat producedwhen using high current during the battery neutralization, formation,and charging process. While this has been successful, it is a highlyrestrictive technique and does not allow individual rectifying circuitcontrol for batteries at various stages of neutralization, formation,and charging. Another method which has been used is the water spray inwhich the batteries are sprayed with water or cooling fluid. Howeverthis approach is not as good as the circulating bath method since thewater spray does not have the heat conducting capacity of the formermethod. Chilled electrolyte has been used as a method of reducing theheat of neutralization. However, this is an expensive method and whileit reduces the high initial peak, the possibility of high heatdeveloping during formation exists as well as the possibility of havinga delayed thermal runaway.

Due to the relatively higher volumes of batteries produced, and theplastic case designs, the various grid alloys and oxide mixtures nowcommonly used in the production of automotive batteries, the prior arttechniques above have not proved satisfactory and relatively longformation times have therefore been necessitated to insure thatoverheating does not occur during formation.

SUMMARY OF THE INVENTION

Applicants' invention basically comprises a battery production methodwherein sets of batteries are placed in a plurality of portable tanks ortubs; the batteries within each tub being electrically interconnectedwithin that tub so that a minimum number of leads are required forsubsequent connection to a charging circuit. The tubs are then stackedat a plurality of heights above the forming room floor and in thepreferred embodiment the tubs are disposed substantially verticallyabove one another. Each tub of batteries is readily interchangeable withthe other tubs in the various vertical positions. Cooling fluid such aswater is introduced at least into the highest tub to a predeterminedlevel above which the water overflows and may begin to fill the adjacentlower tub which in turn overflows to fill the remaining tubs until allthe tubs have been filled with water and are overflowing. Cooling fluidmay also be introduced into other tubs in the vertical array to maintainthe cooling bath between 100° and 125° F. If necessary to keep thetemperature within this temperature range, the overflow cooling fluid orwater coming from the last tub at the lowest position may be conveyed toa cooling tower which removes the heat from the cooling fluid or,alternatively, recycled directly without cooling. In either event atleast some cooling fluid is then conveyed to the tub in the highestposition.

Since each of the tubs of batteries are interchangeable in the variousheights above the floor and further since the cascading action of thewater described above tends to skim off and pass only the warmestportions of the coolant from one tub to the next or to the cooling towerinput, it is possible to establish a flow pattern of coolant so thatimmediately upon its reintroduction into the system from the coolingtower, the coolant may be utilized to service batteries which are mostprone to overheating or thermal runaway. For example, those batteriesnearing the end of the formation process and/or which are being given aboost charge and/or which are of lower capacities and/or are constructedof certain types of grid or paste compositions, may be suitably arrangedin vertical positions to receive the effluent or overflow from "primary"or higher tubs, whereby a given amount of cooling fluid and/or coolingtower capacity cools a maximum number of batteries in a minimum amountof forming room space.

Applicants' invention also includes a process whereby a lower rate ofcurrent is used to pass through the batteries immediately following theintroduction of "one shot" electrolyte into unfilled, unformedbatteries. This avoids unnecessary heat generation while the heat ofneutralization is being reduced or accommodated, while acting as ananti-pickling charge. Following the initial stage, after a predeterminedamount of time, the amount of current is increased until a secondpredetermined period is finished, at which time the current is againlowered during the final formation stage.

Accordingly, a primary object of the present invention is the provisionof a novel method of cooling batteries with plastic cases inneutralization, forming and charging stages.

Another object of the present invention is the provision of a novelmethod which allows individual charging circuit control of batteries invarious stages in neutralization, formation, and charging.

Another aim of the present invention is the provision of a method ofproducing batteries with plastic cases which have been formed underconditions of controlled temperature and time for each of theneutralization, formation, and charging processes.

Another object of the present invention is the provision of a novelmethod of producing batteries with plastic cases which allows the use ofrelatively high charging currents throughout the bulk of the formationprocess.

It is another aim of the present invention to provide a method ofproducing batteries which produces a maximum number of batteries in aminimum amount of forming room floor space.

It is another object of the present invention to provide a method ofcooling batteries during the neutralization, forming, and chargingstates of production which allows individual charging circuit controlsof batteries in various stages of production.

These and other objects of my invention will become apparent from thefollowing description with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of the preferred embodiment process of ourinvention, alternate cooling fluid pathways being shown with brokenlines and arrows;

FIG. 2 is a graph showing the simulated electrolyte temperature of asixty-five amp hour capacity during a conventional formation process,after introducing electrolyte into the battery.

FIG. 3 is a graph showing the electrolyte temperature of a sixty-fiveamp hour capacity battery during the cascade cooling process of ourinvention after filling the battery with electrolyte, using a modifiedconstant voltage technique, where a low initial current charge isprovided by connecting additional resistance across the load in thefirst 5 hours, followed by a constant voltage throughout the remainingformation process;

FIG. 4 is a graph of the temperature of the electrolyte of a sixty-fiveamp hour battery during the preferred embodiment cascade formation ofour invention showing the levels of current provided to the batteries bya rectifying circuit superimposed on the graph, the lower constant finalformation temperature resulting from this process being illustrated tothe right on this graph;

FIG. 5 is a graph showing the temperature of electrolyte in a batteryduring a conventional formation process in which thermal runaway hasoccurred.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although specific forms of the invention have been selected forillustration in the drawings, and the following description is drawn inspecific terms for the purpose of describing forms of the invention,this description is not intended to limit the scope of the invention asdefined in the appended claims.

Referring to FIG. 1, the first step in the preferred process ofapplicants' invention is to separate a plurality of batteries into aplurality of sets, such as sets designated generally 10, 12, and 14 inFIG. 1. The set 10 comprises batteries 16, 18, and 20; the set 12comprises batteries 22, 24, and 26; and the set 14 comprises batteries28, 30, and 32. In the preferred process, this step is not done radomlybut batteries are sorted into sets depending on the capacity, typeand/or stage of formation of these batteries.

After separating the plurality of batteries into a plurality of setssuch as 10, 12, and 14, the next step in applicants' preferred processis to provide a plurality of container means 34, 36, and 38 for holdinga plurality of battery sets such as sets 10, 12, and 14 respectively.These sets are placed into their respective container means andelectrically connected together for connection with a separate externalrectifying circuit. For example, in container No. 34, the battery set 10has the positive terminals connected together to a single power line 42while the negative terminals are all connected to the power line 44. Thepower lines 42 and 44 are readily adaptable to be connected to arectifier for forming and charging the batteries in the set 10. Theremaining sets of batteries shown in FIG. 1 are each individuallyconnected to a separate rectifying source in a similar manner. Thisallows individual circuit controls for each individual set of batteriesin the stack of battery sets. Each of the container means with itsaccompanying set of batteries is then stacked at a plurality ofpositions at different heights above a forming room floor. In FIG. 1,container means 34 is shown above container means 36 and container means36 is shown above container means 38. In the preferred embodiment thecontainer means with the respective set of batteries are stackedvertically above one another.

In the preferred process of applicants' invention, the next step is tocontinuously provide a cooling fluid, such as water, to fill the firstcontainer means 34 with battery set 10 to a predetermined level 50,container means 34 being positioned at the greatest height above theforming room floor 40. The flow of cooling fluid or water from a sourceof water such as cooling tower 46 is represented by the curved line andarrow 48. When the water has reached this level 50, it is allowed tooverflow container 34 and enter a second lower adjacent container meanssuch as container 36 as schematically represented by the line and arrow52. After container means 36 fills to predetermined level 56, the wateroverflows to enter container means 38 (see curved line and arrow 54)whereupon container means 38 fills to predetermined level 58 after whichthe cooling fluid or water overflows to enter the adjacent lowercontainer means or to flow onto the forming room floor, or, as in FIG.1, to be conveyed to cooling tower 46 (see line and arrow 60). Coolingtower 46 or other cooling means acts to remove the heat from the waterwhereupon the cooling water is returned to the highest container means34.

It will be appreciated that as the water passes through the coolingtower 46, a considerable amount of heat is removed and it is desirablethat the batteries sorted into the highest container means such ascontainer means 34 be those batteries most in need of cooling. Ingeneral, these are batteries of higher capacities or batteries which forvarious reasons are prone to generating more heat during the formationor charging processes. Hence, battery set 10 in container means 34 ispreferably a set of unformed high-capacity batteries.

FIG. 2 is a simulated graph of the temperature of electrolyte of asixty-five amp hour capacity batteries as it undergoes a conventional"one shot" modified constant voltage formation process without using thecascading water process of applicants' invention. The ambient roomtemperature and temperature of the filling acid is 90° F. The abscissais Temperature in degrees Fahrenheit and the ordinate is Hours afterfill, that is, hours after filling the battery with electrolyte. In theinitial five hours or so after filling the battery with electrolyte, thetemperature of the electrolyte exceeds 150° F. peaking near 190° F.which is potentially harmful to the battery. After the heat ofneutralization is past, the temperature gradually decreases to below150° F. at 14 hours past filling. Near the end of formation, between 22and 23 hours after filling, when the back voltage of the batteries ishigh and the concentration of the acid is approaching 1.265 specificgravity, the temperature of the electrolyte begins to rise again intothe danger zone above 150° F.

In constrast to FIG. 2, our cooling process in combination with amodified constant voltage process results in a temperature curve shownin FIG. 3; (the abscissa and ordinate being the same). During thisprocess, 100°-125° F. cooling fluid is circulated into contact with 5sides of the batteries. It will be noted that at no time does thetemperature of the electrolyte exceed 150° F., otherwise known as thedanger zone. The heat of neutralization is still present and thetemperature peaks near 150° F. after four hours after filling. However,it gradually decreases to between 110° F. and 130° F. for several hoursbefore rising slightly near the end of formation when the back voltageis high and when, in a "one shot" process, the specific gravityapproaches 1.265. The end of the formation process is critical from atemperature standpoint since separator damage is likely to result atthis time even with slightly elevated i.e., 150+° F., "one shot"end-of-formation temperatures.

FIG. 4 shows the preferred way of controlling the current whilecontinuing the flow of water during the charging process. It is a graphof temperature of electrolyte versus hours after filling as in FIGS. 2and 3. The curve is similar to that of FIG. 3 with the current set at afirst predetermined level during a first predetermined initial period,for example, 5 Amps for the first five hours. Then, after the heat ofneutralization has peaked, the current is raised to a secondpredetermined level for a second predetermined period, for example, 15Amps for fifteen hours. Finally, the current is lowered to a thirdpredetermined level for a third predetermined period, for example, 5Amps for four hours. This third adjustment in current to a lower currentlevel helps to reduce the temperature rise in the electrolyte near theend of formation. This temperature is shown in FIGS. 2 and 3, but not inFIG. 4.

FIG. 5 demonstrates thermal runaway in a battery undergoing formationwhich, sometimes happens when applicants' process is not followed. Acharging level current of 15 Amps is set at the beginning of theformation process and the temperature of the electrolyte increasesbeyond the danger level of 150° due to the heat of neutralization.Because of the accumulation of the heat of neutralization and the heatgenerated by the high charging level of 15 Amps, the temperature of theelectrolyte does not taper off as in FIGS. 2 through 4 to come backbelow the danger level but continues to rise with probable destructionto the battery.

As was previously indicated, batteries at various stages of formationcan be sorted into different sets. Examples of the types of sets thatmay be desired are unformed and unfilled batteries of maintenance free,high antimony types of various uniform capacities, batteries which arepartially formed but not fully charged and batteries which require aboost charge. The amount of heat which the batteries in these differentsets give off will differ. The batteries in the set of highest capacityunformed and unfilled batteries, when the electrolyte is initiallyadded, will generate the greatest amount of heat and therefore, shouldbe placed in a position in the vertical stack of container means whichwill receive the coolest water or cooling fluid. In FIG. 1 this iscontainer means 34 and battery set 10. As the cooling fluid enters thecontainer means 34, the warmer fluid moves gradually to the top with thecooler fluid remaining at the bottom of the container means 34 to enterthe adjacent lower container means 36. Of the sets above described ofbatteries, batteries which are partially formed and not fully chargedwill generate more heat than those batteries which require only a boostcharge. Hence, it is desirable to place this set of batteries as set 12in container means 36. Again the warmest water will gradually move tothe top of the tank to overflow and enter the lower adjacent tank 38.Hence, the warmest water will enter the third tank and batteriesrequiring the least amount of cooling should be placed in this tank. Ofthe battery sets described above, those requiring boost charge willgenerate the least amount of heat and they should be placed in thecontainer means 38 as set 14. As described previously, the warmest waterwill again rise to the top, overflow tank means 38 onto the floor of theforming room or, alternatively, through a purification or neutralizationsystem and then to a cooling tower for return to the vertical array ofcontaining means where it will repeat the cascading process throughseveral container means. The types of sets which might be formed from aplurality of batteries are not limited to the description of the setsgiven above.

The present invention also provides a novel method of utilizing a "oneshot" formation technique in combination with these cooling techniquesto form batteries while achieving improved formation efficiencies.According to the method of the present invention, dry, unformedbatteries of similar cranking capacities may be simultaneously formedusing the same rectification facilities regardless of whether thosebatteries are high antimony lead acid batteries or are maintenance free,i.e., low antimony or calcium lead acid batteries. According to thepreferred method of the present invention, dry, unformed high antimonystock of a preselected cranking capacity and/or dry, unformedmaintenance free stock of a preselected capacity are filled with aconventional relatively higher gravity "one shot" formation electrolyteand then immediately divided into preselected matrix groups. The matrixgroups of high antimony lead acid batteries, preferably comprise a fourby five matrix of approximately twenty batteries per group, while themaintenance free batteries are divided into preselected numbers ofmatrix groups of approximately sixteen-eighteen batteries, preferably ina four by four plus matrix. Each matrix should then preferably beimmediately transferred into cooling tubs, one for each matrix group,each of the batteries within each matrix being spaced apart from itsadjacent batteries by a distance sufficient to allow fluid to freelycirculate therebetween. Once disposed in these tubs, each group is thenpromptly wired in series to interconnect each battery of the group, andeach of the tubs should be arranged in sets of vertical arrays and theconnections from each group connected to individual rectification unitsof a central timing/charging system. Thereafter a three phase chargingprocess should immediately be begun. In the first phase, circulation ofa cooling fluid, preferably water, which is maintained at a tempertureof about 100°-125° F. should be circulated through each of the tubs. Afixed amperage "anti-pickling" charge is applied at this point, at arate of 4 to 6, preferably 5, amps for 1-5 hours, preferably 2-3 hours,during which time the heat of neutralization is dissipated into thecooling fluid and the exothermic chemical reactions between theelectroylte and the battery plate materials will have passed a pointwhere thermal runaway is likely to occur. The preferred electrolyte foruse in this method is a conventionally, relatively higher gravity "oneshot" formation electrolyte as for example, a sulphuric acid electrolytecontaining 30-40 grams per liter of sodium sulphate and, having aspecific gravity of between 1150 and 1220, the particular gravity to beused having been determined according to the relative capacities of thebatteries to be formed.

At the completion of phase one of the charging cycle, the circulation of100°-125° F. cooling fluid is continued, while the rate of charge isautomatically shifted into a variable length charge cycle at a rate of15-18 amps for a preselected time "y" where "y" is greater than 3.8×-86and is less than 4.6×-24, and preferably, between 4.0×-57 and 4.5×-40,suitable complete formations having been obtained when "y" was equal to4× minus 40, the higher values (i.e., up to 4.5×) being necessary onlyto compensate for capacity variations within a matrix set which resultsfrom slightly different oxide amounts etc. from battery to battery.

At the completion of phase 2 of the charging cycle, circulation ofcooling fluid having temperatures between 100°-125° F. is continuedwhile the charging system is automatically shifted to a "clearingcharge" of a 4 to 8 preferably 5-7 amp rate for 5 to 7, preferably 6hours.

As mentioned above, the preferred temperature of cooling fluidcirculated around the batteries to be formed is between 100°-125° F. Itwould, of course, be possible particularly during the colder wintermonths, to chill water or other cooling fluids substantially below thepreferred minimum 100° F. Applicants have found, however, that suchchilling of the cooling fluid to such temperatures is not desirable, andif complete formation is to be obtained using the "one shot" formationprocess, it is extremely desirable to maintain the batteries to beformed in a bath which is controlled within this temperature rangethroughout all phases of the formation and charging process. As shown inparticular in FIGS. 3 and 4, the maintenance of cooling fluidtemperatures in this range insures that from at least one hour afterfilling through to the end of the entire formation process, theelectrolyte temperatures are maintained between 110° F. and 150° F. andpreferably during the later phases of the formation process stablizedbetween 120° and 130° F., and preferably about 125° F. It is theorizedthat rigorous control of the electrolyte temperatures of batteriesundergoing a formation process enables that formation to proceed at anoptimum rate, that is, by maintaining the formation electrolyte withinthis desired temperature range the thermodynamics of the primary andsecondary reactions occurring during formation are shifted so thatreaction kinetics more strongly favor complete formation of the activepaste materials while shifting the reaction kinetics away from secondaryreactions which may compete with the primary reaction for startingmaterials while producing end product complexes acting as inhibitors ofthe primary reaction to thereby reduce the overall yield of the primaryreaction, i.e., the completeness of formation. Accordingly, as seen inparticular in FIG. 1, alternate circulation pathways are provided forensuring that the temperature of the cooling fluid is maintained withinthis optimum range. It may, for example, be desirable to introducecooling fluid as for example by pathway 100 directly into a tub fromwhich that cooling fluid is removed for return to the cooling tower 46.Alternatively, as shown via pathway 102, it may be desired to returncooling fluid to the cooling tower after it has passed through aplurality of tubs, but less than all the tubs in a vertical array.Finally, as illustrated by pathway 104, it may be desired, particularlyin colder weather, to shunt some or all of the cooling fluid by thecooling tower 46 so that the cooling fluid is rapidly raised byrecirculation to the desired temperature range.

Using the method of the present invention, complete formation may beobtained using relatively less current that that heretofore necessary tocomplete formation. Thus, considerable success has been achieved incompleting the formation of, for example, a 300 amp hour battery byapplying a total of approximately 1200 amp hours of formation current tothat battery, instead of the heretofore industry wide acceptablestandard of 4.5 times the number of amp hours of battery capacity, or1350 amp hours for a 300 amp hour battery. This savings of approximately8% in the total current required to charge a battery is coupled with asubstantial decrease in the formation time required for the battery.While under production conditions, it is advisable to use closer to 4.5times the amp hour of battery capacity to compensate for individualbattery variations, corresponding increases in efficiency are believedto nonetheless be maintained under these conditions.

Accordingly, instead of continuously charging a battery at a constantlow amperage rate for longer periods of time, shorter charging cyclescharging cycle may now be established, thereby enabling a given batteryproduction facility to run on a five day work week instad of theheretofore required seven day work week. Due to the nature of thischarging technique, considerable overtime expenses have accordingly beeneliminated through the use of this method.

It will be understood that various changes in the details, materials andarrangement of parts which have been herein described and illustrated inorder to explain the nature of this invention may be made by thoseskilled in the art within the principle and scope of the invention asexpressed in the following claims.

It will further be understood that the "Abstract of the Disclosure" setforth above is intended to provide a non-legal technical statement ofthe contents of the disclosure in compliance with the Rules of Practiceof the United States Patent and Trademark Office, and is not intended tolimit the scope of the invention described and claimed herein.

What is claimed is:
 1. A method for producing batteries having plasticcases comprising the steps of:(a) separating a plurality of batteriesinto a plurality of sets, said separating comprising sorting batterieswhich are at a similar stage of formation into a single set, saidseparating further comprising the step of sorting a plurality ofunformed batteries of a preselected cranking capacity immediately intosets after filling with "one shot" formation electrolyte; (b) providinga plurality of container means for holding a plurality of battery sets;(c) placing said sets of batteries into said container means, one setfor each container means and electrically interconnecting said batteriesin each set for connection to a separate rectifying means for each set;(d) stacking said plurality of container means at a plurality ofpositions at different heights above a forming room floor; (e)connecting each set of said batteries to said separate rectifying meansfor charging said plurality of batteries in each set; (f) continuouslyproviding cooling fluid to maintain each of said plurality of containermeans at a predetermined level, and to circulate said cooling fluidtherethrough by causing said cooling fluid to overflow from saidcontainer means; and (g) forming said sets with said rectifying meanswhile maintaining said cooling fluid within each of said container meansat a temperature of between 100° to 125° F., said step of maintainingsaid cooling fluid at said temperature further comprising the stepsof:(i) conveying said overflow cooling fluid from said container meansto a heat removing means for removing heat from said cooling fluid; and(ii) returning said cooling fluid from said heat removing means to saidcontainer means.
 2. The method of claim 1 wherein said forming stepcomprises the steps of (1) applying a first constant length formationcurrent of between 4 and 6 amps for 1 to 5 hours; whereby heat ofneutralization and plate pickling are controlled, and (2) applying asecond formation current at 15 to 18 amps for a predetermined number ofhours "y" where "y" is greater than 3.8×-86 and is less than 4.6×-24,"x" being the capacity of each of said batteries in said set, and then(3) applying a finishing current of 4 to 8 amps for 5 to 7 hours, tothereby complete formation of the batteries in said set.
 3. Theinvention of claim 2 wherein said first formation current is applied at5 amps for 2 to 3 hours.
 4. The invention of claim 2 wherein said secondcurrent is applied for between 4.0×-57 and 4.5×-40 hours.
 5. Theinvention of claim 4 wherein said second current is applied for about4.0×-40 hours.
 6. The invention of claim 2 wherein the temperature ofsaid electrolyte is maintained by said cooling fluid below apredetermined temperature.
 7. The invention of claim 6 wherein saidpredetermined temperature is 150 degrees Fahrenheit.